Plastic conversion unit and plastic processing system to efficiently reduce carbon footprints in refining systems and petrochemical processing systems.

Abstract

Methods, systems, and apparatus for blending plastic to efficiently reduce carbon footprints in refining systems and petrochemical processing systems. Aspects of the present disclosure relate to methods, systems, and apparatus for efficiently reducing carbon footprints in refining systems and petrochemical processing systems. In one aspect, a plastic powder feedstock is blended into a processing system feedstock to reuse plastic and reduce carbon footprints. In one implementation, a method of blending plastics into a processing system includes spraying a plastic supply onto a plastic stock that has a granule size that lies in a range of 7 nanometers to 10 nanometers. The method includes separating the plastic stock to remove a portion that has a granule size that is outside the 7 nanometer to 10 nanometer range and generating a plastic feedstock.The method involves blending the plastic raw material into a raw material from the processing system to generate a blended raw material, and then processing the blended raw material.

Description

1 / 20 “PLASTIC CONVERSION UNIT AND PLASTIC PROCESSING SYSTEM TO EFFICIENTLY REDUCE CARBON FOOTPRINTS IN REFINING SYSTEMS AND PETROCHEMICAL PROCESSING SYSTEMS” BACKGROUND Field

[001] Aspects of the present disclosure relate to methods, systems and apparatus for efficiently reducing carbon footprints in refining systems and petrochemical processing systems. In one aspect, a plastic feedstock is blended into a feedstock of a processing system to reuse plastic and reduce carbon footprints. Description of the Related Technique

[002] Many plastics produced today are not recycled or reused, but rather wasted, such as when sent to a landfill. Consequently, the plastics produced can involve a carbon footprint, due to the production of wasted plastic and the CO2 emissions associated with it.

[003] Therefore, there is a need for methods, systems and equipment that facilitate the reuse of plastic in refining systems and petrochemical processing systems to facilitate reduced carbon footprints, increased economics and increased operational efficiency (such as thermal efficiency) for refining systems and petrochemical processing systems. SUMMARY

[004] Aspects of the present disclosure relate to methods, systems and apparatus for efficiently reducing carbon footprints in refining systems and petrochemical processing systems. In one aspect, a plastic feedstock is blended into a feedstock of a processing system to reuse plastic and reduce carbon footprints.

[005] In one implementation, a method of merging plastics into a Petition 870250015048, dated 24 / 02 / 2025, page 9 / 60 The 2 / 20 processing system involves spraying a supply of plastic onto a plastic feedstock that has a granule size within the range of 7 nanometers to 10 nanometers. The method includes separating the plastic feedstock to remove a portion that has a granule size outside the 7-10 nanometer range and generating a plastic feedstock. The method also includes blending the plastic feedstock into the processing system feedstock to generate a blended feedstock, and processing the blended feedstock.

[006] In one implementation, a plastic converting unit includes a primary hopper configured to receive a supply of plastic, and a primary shredder that includes an outlet and an inlet coupled to an outlet of the primary hopper. The primary shredder is configured to shred the plastic supply to a first granule size that is less than 5 millimeters. The plastic converting unit includes a primary classifier that includes an outlet and an inlet coupled to the outlet of the primary shredder. The plastic converting unit includes a secondary hopper that includes an outlet and an inlet coupled to the outlet of the primary classifier. The plastic converting unit includes a secondary granulator that includes an outlet and an inlet coupled to the outlet of the secondary hopper.The secondary granulator is configured to grind the plastic supply into a plastic feedstock that has a second granule size that falls within the range of 10 nanometers to 0.1 microns. The plastic converting unit includes a secondary classifier that includes an outlet and an inlet coupled to the outlet of the secondary granulator. The secondary classifier is configured to separate the plastic feedstock to remove a portion (e.g., particles) that has a granule size that is outside the range of 10 nanometers to 0.1 microns and generate a plastic feedstock.

[007] In one implementation, a processing system includes a Petition 870250015048, dated 24 / 02 / 2025, page 10 / 60 3 / 20 plastic converting unit coupled to one or more raw material lines. The plastic converting unit includes a primary hopper configured to receive a supply of plastic and a primary shredder that includes an outlet and an inlet coupled to an outlet of the primary hopper. The primary shredder is configured to shred the plastic supply to a first granule size that is less than 5 millimeters. The plastic converting unit includes a primary classifier that includes an outlet and an inlet coupled to the outlet of the primary shredder. The plastic converting unit includes a secondary hopper that includes an outlet and an inlet coupled to the outlet of the primary classifier. The plastic converting unit includes a secondary granulator that includes an outlet and an inlet coupled to the outlet of the secondary hopper.The secondary granulator is configured to grind the plastic supply into a plastic feedstock that has a second granule size that falls within the range of 10 nanometers to 0.1 microns. The plastic conversion unit includes a secondary classifier that includes an outlet and an inlet coupled to the outlet of the secondary granulator. The secondary classifier is configured to separate the plastic feedstock to remove a portion that has a granule size that is outside the range of 10 nanometers to 0.1 microns and generate a plastic feedstock. BRIEF DESCRIPTION OF THE DRAWINGS

[008] In order that the manner in which the characteristics of the revelation mentioned above may be understood in detail, a more particular description of the revelation, briefly summarized above, may be taken as a reference to the modalities, some of which are illustrated in the attached drawings. It should be noted, however, that the attached drawings illustrate only typical modalities of this revelation and are therefore not considered limiting to its scope, for other equivalently effective modalities must be admitted for the revelation. Petition 870250015048, dated 24 / 02 / 2025, page 11 / 60 4 / 20

[009] Figure 1 is a partial schematic view of a plastic converting system having a plastic converting unit, according to one implementation.

[010] Figure 2 is a schematic view of a processing system that has the plastic conversion unit shown in Figure 1, according to one implementation.

[011] Figure 3 is a schematic block diagram view of a method for merging plastics in a processing system, according to one implementation.

[012] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements revealed in one implementation may be used beneficially in other implementations without specific mention. DETAILED DESCRIPTION

[013] Aspects of the present disclosure relate to methods, systems and apparatus for efficiently reducing carbon footprints in refining systems and petrochemical processing systems. In one aspect, a plastic feedstock is blended into a feedstock of a processing system to reuse plastic and reduce carbon footprints.

[014] The present disclosure contemplates that the use of terms such as “coupled”, “coupled”, “couplings” and / or “coupling” may include direct coupling and / or indirect coupling, such as coupling through other components. The present disclosure also contemplates that the use of terms such as “coupled”, “couplings”, “coupled” and / or “coupling” may include connection, welding and / or fastening with the use of fasteners, such as pins, rivets, screws, dowels and / or nuts. The present disclosure also contemplates that the use of terms such as “coupled”, “couplings”, “coupled” and / or “coupling” may include fluid coupling, such as a or Petition 870250015048, dated 24 / 02 / 2025, page 12 / 60 5 / 20 more connections to establish fluid communication.

[015] Figure 1 is a partial schematic view of a plastic conversion system 100 having a plastic conversion unit 110, according to one implementation. A transport system 101 transports a supply of plastic, such as from a recycling center to a supply treatment system 103. The transport system 101 may include, for example, a train, a truck, and / or a sea vessel. The supply of plastic is in the form of bales, such as compacted bales that are compacted at the recycling center. However, other forms of supply are also contemplated. The supply of plastic may be purified (such as through the use of magnets) at the recycling center to remove contaminants such as metals. The supply treatment system 103 unpacks the bales of the supply of plastic to break the bales into separate components. The supply treatment system 103 also sorts, washes, and dries the supply of plastic.A handling system 105 transfers the plastic supply from the supply treatment system 103 to a plastic converting unit 110. The handling system 105 may include a crane and / or a mechanical conveyor.

[016] The plastic converting unit 110 includes a primary hopper 111 configured to receive the plastic supply from the handling system 105. An inlet of the primary hopper 111 receives the plastic supply from the handling system 105. A primary shredder 113 includes an outlet and an inlet coupled to the outlet of the primary hopper 111. The primary shredder 113 is configured to shred the plastic supply to a first granule size that is less than 5 millimeters. The primary shredder 113 includes one or more rotary cutters that have blades that cut the plastic supply to shred the plastic supply to the first granule size. A first feeder 112, such as a ramp, is coupled between the outlet of the primary hopper. Petition 870250015048, dated 24 / 02 / 2025, page 13 / 60 6 / 20 111 and the primary shredder inlet 113. A primary classifier 115 includes an outlet and an inlet coupled to the outlet of the primary shredder 113. The primary classifier 115 separates a portion (e.g., particles) from the plastic supply that has a granule size of 5 millimeters or larger, removes the portion from the plastic supply, and returns the portion to the primary hopper 111 to be shredded by the primary shredder 113. The portion is returned to the primary hopper 111 via a primary return line 116. A second feeder 114, like a ramp, is coupled between the outlet of the primary shredder 113 and the inlet of the primary classifier 115.

[017] The remainder of the plastic supply (besides the portion returned to the primary hopper 111) is supplied by the outlet of the primary classifier 115 and to an inlet of the secondary hopper 117. The secondary hopper 117 includes an outlet and an inlet coupled to the outlet of the primary classifier 115. The plastic conversion unit 110 includes a secondary granulator 119. The secondary granulator 119 includes an outlet and an inlet coupled to the outlet of the secondary hopper 117. The secondary granulator 119 is configured to grind the plastic supply into a plastic feedstock that has a second granule size that lies in a range of 10 nanometers to 0.1 microns. A third feeder 118, like a ramp, is coupled between the outlet of the secondary hopper 117 and the inlet of the secondary granulator 119.The secondary granulator 119 includes two bearings with the plastic supply being fed between the two bearings so that the plastic supply is mechanically crushed between the two rotating bearings.

[018] A secondary classifier 121 includes an outlet and an inlet coupled to the outlet of the secondary granulator 119. A fourth feeder 120, like a ramp, is coupled between the outlet of the secondary granulator 119 and the inlet of the secondary classifier 121. The secondary classifier 121 is configured to Petition 870250015048, dated 24 / 02 / 2025, page 14 / 60 7 / 20 separate the plastic raw material to remove a portion that has a granule size that is outside the size range of the second granule size from 10 nanometers to 0.1 microns. The removed portion of the plastic supply is returned to the secondary hopper 117 via a secondary return line 122. The remainder of the plastic supply (besides the portion returned to a secondary hopper 117) is supplied by the outlet of the secondary classifier 121 and to an inlet of a tertiary hopper 125. The remaining plastic supply, which is supplied to the tertiary hopper 125, is a plastic raw material generated using the secondary granulator 119 and the secondary classifier 121.

[019] A first pneumatic conductor line 124 is coupled between the outlet of the secondary classifier 121 and the inlet of the tertiary hopper 125. The first pneumatic conductor line 124 is coupled to an outlet of the secondary classifier 121 via a first rotary air block 123. A first air source 126 supplies air to the first pneumatic conductor line 124 to facilitate the supply of plastic raw material to the tertiary hopper 125. The tertiary hopper 125 includes an outlet, and the inlet of the tertiary hopper 125 is coupled to an outlet of the secondary classifier 121 via the first pneumatic conductor line 124 and the first rotary air block 123.

[020] A tertiary grinding mill 129 includes an outlet and an inlet coupled to the outlet of the tertiary hopper 125 via a fifth feeder 128, as a ramp. A tertiary classifier 130 includes an outlet and an inlet coupled to the outlet of the tertiary grinding mill 129. The tertiary grinding mill 129 mechanically grinds at least a portion of the plastic raw material that is larger than 10 nanometers to be one-third granule size that lies in a range of 7 nanometers to 10 nanometers. The tertiary grinding mill 129 may mechanically grind at least a portion of the plastic raw material using one or more wet grinding or cryogenic grinding methods. Petition 870250015048, dated 24 / 02 / 2025, p. 15 / 60 8 / 20

[021] The present disclosure contemplates that the operations of the primary shredder 113, the secondary granulator 119 and the tertiary grinding mill 129 can be carried out by a single grinding mill. By using the primary shredder 113, the secondary granulator 119 and the tertiary grinding mill 129 in the multi-stage grinding described, grinding efficiency is facilitated with increased particle size distribution, achieving the third granule size and saving energy.

[022] A tertiary classifier 130 is configured to separate the plastic raw material to remove a portion (e.g., particles) that have a granule size that is outside the third granule size range of 7 nanometers to 10 nanometers. A tertiary return line 131 returns the portion removed by the tertiary classifier 130 to the tertiary hopper 125 to be crushed by the in-line classifier by the tertiary crushing mill 129. The primary classifier 115, the secondary classifier 121, and the tertiary classifier 130 are in-line classifiers. Each of the primary classifier 115, the secondary classifier 121, and / or the tertiary classifier 130 may be a centrifuge, an electrophoretic classifier, and / or a sound wave-activated nanosieve classifier. The present disclosure contemplates that other classifiers may be used.

[023] A second pneumatic conductor line 134 is coupled between the outlet of the tertiary classifier 130 and an inlet of a plastic storage tank 135. The second pneumatic conductor line 134 is coupled to an outlet of the tertiary classifier 130 via a second rotary air lock 132. A second air source 133 supplies air to the second pneumatic conductor line 134 to facilitate the supply of plastic raw material to the plastic storage tank 135. The first air source 126 and the second air source 133 can be integrated into a single air source. One or more compressors can be used to deliver pressurized air from the first and second sources. Petition 870250015048, dated 24 / 02 / 2025, page 16 / 60 9 / 20 air 126, 133. The inlet of the plastic storage tank 135 receives the plastic raw material. An outlet of the plastic storage tank 135 is coupled to one or more lines 137 (such as a crude oil line, a vacuum gas oil line and / or a vacuum bottom line, as discussed in relation to Figure 2) of a processing system. The outlet of the plastic storage tank 135 is coupled to one or more lines 137 via a screw feeder 136. The plastic raw material stored in the plastic storage tank 135 includes one or more polyolefins, such as one or more of high-density polyethylene (HDPE), low-density polyethylene (LDPE), colored HDPE, polypropylene (PP), polystyrene (PS), Grade A film, Grade B film, and / or Grade C film. The plastic storage tank 135 can be configured to store 3-5 minutes of flow of plastic raw material.A hopper can be coupled between the plastic storage tank 135 and the screw feeder 136 to feed the plastic raw material into the screw feeder 136. The present disclosure contemplates that the plastic storage tank 135 and / or the screw feeder 136 can be omitted or avoided, and the plastic raw material can be supplied from the second pneumatic conveyor line 134 and directly to the screw feeder 136 or to one or more lines 137.

[024] The plastic raw material stored in the plastic storage tank 135 is blended into a raw material in which one or more lines 137 at a temperature of approximately 70 degrees Celsius, as within a range of 65 degrees Celsius to 75 degrees Celsius. The plastic supply and the plastic raw material flow through the plastic converting unit 110 at a temperature of approximately 70 degrees Celsius, as within a range of 65 degrees Celsius to 75 degrees Celsius.

[025] The primary shredder 113 conducts a primary shredding operation, the secondary granulator 119 conducts a secondary shredding operation, Petition 870250015048, dated 24 / 02 / 2025, page 17 / 60 The 10 / 20 and tertiary crushing mill 129 conducts a tertiary crushing operation to mechanically pulverize the plastic supply and generate plastic feedstock that has the third granule size. The plastic feedstock includes pulverized plastic powder blended in crude or heavy oil. The pulverized plastic powder can then be blended in crude or heavy oil. The primary crushing operation is a macro-crushing operation, the secondary crushing operation is a micro-crushing operation, and the tertiary crushing operation is a nano-crushing operation.

[026] The present disclosure contemplates that the plastic feedstock can be blended with crude or heavy oil before being blended in one or more lines 137 (such as the crude oil line 201 discussed below). In such embodiment, the pre-blended plastic feedstock is fed to one or more lines 137 for reprocessing of the already blended plastic feedstock.

[027] The present disclosure contemplates that the plastic converting unit 110 may include one or more heaters 150 that melt the plastic supply into a molten plastic that has the third granule size. One or more heaters 150 can be used in addition to or in place of the primary shredder 113, the secondary granulator 119, and / or the tertiary grinding mill 129. In the implementation shown in Figure 1, the one or more heaters 150 are coupled to a heater inlet line 151 which is coupled to a line 152 that extends between the primary classifier 115 and the secondary hopper 117. The portion of the plastic supply that is provided from the primary classifier 115 to the secondary hopper 117 is provided to the one or more heaters 150. The one or more heaters 150 heat the plastic supply to a melting temperature above 70 degrees Celsius, such as 100 degrees Celsius or higher.One or more heaters 150 may include, for example, one or more boilers and / or one or more resistive heaters. The present disclosure contemplates that the primary shredder... Petition 870250015048, dated 24 / 02 / 2025, p. 18 / 60 11 / 20 113, the secondary granulator 119, and the tertiary grinding mill 129 may be omitted, and one or more heaters 150 may be used to heat the plastic supply to molten plastic having the third granule size. A heater outlet line 153 is coupled to one or more heaters 150 to supply molten plastic having the third granule size to one or more lines 137. A second plastic storage tank (similar to plastic storage tank 135) and a second feeder screw (similar to feeder screw 136) may be coupled to the heater outlet line 153 to supply molten plastic to one or more lines 137.

[028] The present disclosure contemplates that the heat generated by the use of mechanical grinding can melt at least a portion of the plastic supply and / or the plastic feedstock into molten plastic. Each of the primary grinding operation, the secondary grinding operation and the third grinding operation can be wet or dry.

[029] The plastic converting unit 110 is configured to supply the plastic raw material to the plastic storage tank 135 according to a P80 classification so that 80% or more of the plastic raw material received in the plastic storage tank 135 has a granule size within a range of 7 nanometers to 10 nanometers.

[030] Figure 2 is a schematic view of a processing system 200 having the plastic conversion unit 110 shown in Figure 1, according to one implementation. The processing system 200 is a refining and petrochemical processing system. The plastic conversion unit 110 mixes the plastic feedstock with feedstock in lines of the processing system 200. The outlet of the plastic storage tank 135 is coupled to one or more of a crude oil line 201, a vacuum gas oil line 202 and / or a vacuum bottom line 203. The crude oil line 201 includes a material Petition 870250015048, dated 24 / 02 / 2025, page 19 / 60 12 / 20 raw material containing crude oil. Vacuum diesel line 202 includes a raw material containing one or more of a diesel, a heavy oil, a diesel, a carbon black feedstock (CBFS) and / or a material in the naphtha range. The heavy oil may include paraffin wax, which may be used as a lubricating fluid. Vacuum bottom line 203 includes a raw material containing one or more of a diesel, a heavy oil, a diesel, a carbon black feedstock (CBFS) and / or a material in the naphtha range.

[031] The crude oil line 201 feeds an atmospheric distillation unit 204 which is coupled to a vacuum distillation unit 205. The vacuum gas oil line 202 feeds one or more crackers, such as a thermal cracker, a catalytic cracker 206 (such as a fluid catalytic cracker (FCC)) and / or a hydrocracker 207. The hydrocracker 207 may include LCfining operations. The vacuum bottom line 203 feeds one or more of a deasphalter 208 (such as a propane deasphalter), a viscoreduction unit 209 and / or a coker 210 (such as a delayed coking unit (DCU) and / or a flexi-coker). Vacuum diesel line 202 feeds heavy atmospheric diesel line 211. Vacuum diesel line 202, vacuum bottom line 203 and heavy atmospheric diesel line 211 may include bottom barrel feedstock. A first hydrotreating unit 212 is coupled between heavy atmospheric diesel line 211 and catalytic cracker 206.A second hydrotreating unit 213 is coupled between a naphtha line 214 and a catalytic reforming unit 215.

[032] A middle distillate line 216 is coupled between the atmospheric distillation unit 204 and a third hydrotreating unit 217. A straight gasoline line 218 and a liquefied petroleum gas (LPG) and gas line 219 also exit the atmospheric distillation unit 204. A lubricant base stock line 220 is coupled between the vacuum distillation unit 205 and a unit Petition 870250015048, dated 24 / 02 / 2025, page 20 / 60 13 / 20 of solvent extraction 221. A cycle oil line 222 is coupled between the catalytic cracker 206 and the hydrocracker 207. The LPG and gas line 219 feeds LPG into an alkylation unit 223. The alkylation unit 223 feeds alkylate into treatment and blending operations 225. A reformatting line 224 is coupled between the catalytic reforming unit 215 and the treatment and blending operations 225. A gasoline line 226 and a pulp oil line 227 are each coupled between the catalytic cracker 206 and the treatment and blending operations 225. An outlet 228 from the hydrocracker 207 feeds one or more of gasoline, a material from the Naphtha range and / or middle distillates into treatment and blending operations 225.

[033] A first outlet 229 of the coker 210 feeds LPG and gas to the LPG and gas line 219. A second outlet 230 of the coker 210 feeds one or more of gasoline, a material from the Naphtha range and / or middle distillates into treatment and blending operations 225. A third outlet 231 of the coker 210 releases coke. A lubricating oil line 233 is coupled between a solvent dewaxing unit 232 and treatment and blending operations 225. The lubricating oil line 233 feeds lubricating oils into treatment and blending operations 225. A wax line 234 is coupled between the solvent dewaxing unit 232 and treatment and blending operations 225 to feed waxes into treatment and blending operations 225.

[034] A first outlet 235 of the viscoreduction unit 209 feeds asphalt into treatment and blending operations 225. A second outlet 236 of the viscoreduction unit 209 feeds fuel oils into treatment and blending operations 225. The third outlet 237 of the viscoreduction unit 209 feeds one or more of gasoline, a material from the Naphtha range and / or middle distillates into treatment and blending operations 225. A fourth outlet 238 of the viscoreduction unit 209 feeds LPG and gas to the LPG and gas line 219. Petition 870250015048, dated 24 / 02 / 2025, page 21 / 60 14 / 20

[035] Treatment and blending operations 225 include a plurality of outputs 241-251. A first output 241 releases fuel gas in a refinery. A second output 242 releases LPG. A third output 243 releases gasoline. A fourth output 244 releases solvents. A fifth output 245 releases kerosene. A sixth output 246 releases diesel. A seventh output 247 releases heating oil. An eighth output 248 releases lubricating oil. A ninth output 249 releases greases. A tenth output 250 releases asphalt. An eleventh output 251 releases industrial fuels.

[036] The plastic feedstock (which includes pulverized plastic powder) from the plastic converting unit 110 is mixed into the respective feedstock from one or more of the crude oil line 201, the vacuum gas oil line 202 and / or the vacuum bottom line 203. In the implementation shown in Figure 2, the molten plastic generated using one or more heaters 150 (which receive the plastic supply from the primary shredder 113) is also mixed as plastic feedstock in one or more of the crude oil line 201, the vacuum gas oil line 202 and / or the vacuum bottom line 203. The one or more heaters 150 are coupled to one or more power sources 155 to heat the plastic supply and melt the plastic supply. Since one or more energy sources 155 are electrical sources, such as voltage sources, for example, direct current (DC) voltage sources.The plastic feedstock (which may include pulverized plastic powder and / or molten plastic) is blended into the respective feedstock of each line 201, 202 and / or 203 to generate a blended feedstock in each line 201, 202 and / or 203. The blended feedstock in each line 201, 202 and / or 203 is an enhanced olefin feedstock. The plastic feedstock is blended into the respective feedstock of each line 201, 202 and / or 203 at a volumetric ratio of the plastic feedstock relative to the respective feedstock. The volumetric ratio is in a range of 10:90 to 20:80, such that the plastic feedstock is in a range of 10 percent to 20 percent (by volume) of the... Petition 870250015048, dated 24 / 02 / 2025, p. 22 / 60 15 / 20 respective raw material blended in each line 201, 202 and / or 203. The plastic raw material is blended into the respective raw material of each line 201, 202 and / or 203 at a mass ratio and a molar ratio where each corresponds to the volumetric ratio that depends on the density of the plastic raw material.

[037] The 110 plastic conversion unit is a modular unit that can be coupled (e.g., bolted) to various refining and petrochemical processing systems so that refining and petrochemical processing systems can be installed to blend waste plastic into petrochemical feedstock(s). The aspects of the 110 plastic conversion unit and the 200 processing system facilitate the use of existing petrochemical processing and refining infrastructure for blending plastics, thereby reducing costs and extending the operational lives of refining and petrochemical processing equipment and infrastructure.

[038] Figure 3 is a schematic block diagram view of a method 300 for blending plastics in a processing system, according to one implementation. The processing system may be a petrochemical and refining processing system. In one embodiment, which may be combined with other embodiments, the processing system is a crude oil processing system. Operation 302 involves pulverizing and / or melting a plastic supply into a plastic feedstock that has a granule size that lies in a range of 7 nanometers to 10 nanometers. The granule size may be of a diameter or width. The plastic supply includes one or more of a plastic scrap (such as recycled plastic). The plastic supply includes one or more of high-density polyethylene (HDPE), low-density polyethylene (LDPE), colored HDPE, polypropylene (PP), polystyrene (PS), Grade A film, Grade B film, and / or Grade C film.The plastic supply may include designated plastic recycling numbers 2, 4, 5, 6 and / or 7. Petition 870250015048, dated 24 / 02 / 2025, page 23 / 60 16 / 20

[039] The pulverization of the plastic supply in operation 302 includes mechanically shredding the plastic supply. In one embodiment, which may be combined with other embodiments, the mechanical shredding of the plastic supply includes conducting a primary shredding operation using one or more shredders, and conducting a secondary shredding operation using one or more granulators. In such an embodiment, the mechanical shredding of the plastic supply also includes conducting a tertiary shredding operation using one or more shredding mills. In such an embodiment, the plastic feedstock that has the granule size includes plastic powder. In one embodiment, which may be combined with other embodiments, operation 302 includes conducting a primary shredding operation on the plastic supply using one or more shredders, and heating the plastic supply to melt the plastic supply into a molten plastic.In this type of product, the plastic raw material, which is granule-sized, includes molten plastic.

[040] Operation 304 involves separating the plastic feedstock to remove a portion that has a granule size outside the 7 nanometer to 10 nanometer range and generating a plastic feedstock. The plastic feedstock includes polyolefins. Mechanical pulverization and / or smelting and the use of polyolefins facilitate the restoration of the plastic to high-value virgin levels (which can be used to generate high-value petrochemicals) at a low-energy conversion, facilitating the reuse of waste plastics in an economical way.

[041] Optional operation 305 includes storing the plastic raw material in a plastic storage tank.

[042] Operation 306 involves blending the plastic feedstock into a feedstock from the processing system to generate a blended feedstock. The blended feedstock is a homogeneous solution. The blended feedstock is an olefin-enhanced feedstock. In one embodiment, which may be Petition 870250015048, dated 24 / 02 / 2025, page 24 / 60 In one embodiment, which can be combined with other embodiments, the raw material is located in a vacuum gas oil line. In another embodiment, which can be combined with other embodiments, the raw material includes crude oil. In another embodiment, which can be combined with other embodiments, the raw material is located in a vacuum bottom line. In another embodiment, which can be combined with other embodiments, the raw material includes one or more of a carbon black feedstock (CBFS), crude oil, diesel, heavy oil, gas oil, and / or a material in the naphtha range. In another embodiment, which can be combined with other embodiments, the mixing of the plastic feedstock into the raw material includes rotating a feeder screw to supply the plastic feedstock to the raw material.

[043] The blending in the 306 operation can be simple injection or high shear mixing. The blending in the 306 operation occurs at approximately 70 degrees Celsius, as within a range of 65 degrees Celsius to 75 degrees Celsius. The plastic feedstock is blended into the processing system feedstock at a volumetric ratio within a range of 10:90 to 20:80. The blending in the 306 operation facilitates the reduction of operating costs and the reduction of hydrocarbon consumption (such as crude oil) in refining plants and petrochemical processing plants. The blending also facilitates the reduction of plastic pollution while making use of recycled plastic to generate high-value petrochemicals, as when compared to lower-value synthetic fuels.The plastic feedstock is a heavy fuel (containing valuable hydrocarbons) that is similar to a wax material and is suitable for blending with other (also heavy) feedstocks in the processing system while facilitating the benefits described in this document.

[044] Operation 308 includes processing blended feedstock. In one embodiment, which may be combined with other embodiments, processing blended feedstock includes cracking the blended feedstock in one or more of a thermal cracker, a hydrocracker, and / or a cracker. Petition 870250015048, dated 24 / 02 / 2025, page 25 / 60 18 / 20 catalytic. In one embodiment, which may be combined with other embodiments, the processing of the blended feedstock includes distilling the blended feedstock in one or more of an atmospheric distillation unit and / or a vacuum distillation unit. In another embodiment, which may be combined with other embodiments, the processing of the blended feedstock is conducted in one or more of a deasphalter, a viscoreduction unit and / or a coking plant.

[045] The modalities of the present disclosure can be expressed in Example 1 below.

[046] Example 1 includes a method of blending plastics in one or more feedstock lines of a processing system. The method includes mechanically spraying and / or heating a supply of plastic into a plastic feedstock that has a granule size that is in the range of 7 nanometers to 10 nanometers. The method also includes separating the plastic feedstock to remove a portion that has a granule size that is outside the range of 7 nanometers to 10 nanometers and generating a plastic feedstock.

[047] The method of Example 1 also includes blending the plastic feedstock into a crude oil from the processing system at a temperature of about 70 degrees Celsius, as within a range of 65 degrees Celsius to 75 degrees Celsius. The plastic feedstock is blended into crude oil at a volumetric ratio within a range of 10:90 to 20:80 to generate a blended feedstock. The blended feedstock (which has the plastic feedstock and the crude oil) is distilled in an atmospheric distillation unit and in a vacuum distillation unit to generate one or more gas oils. The blended feedstock is distilled in the atmospheric distillation unit at atmospheric pressure and a temperature that is less than the boiling point (e.g., a temperature above 350 degrees Celsius) of the blended feedstock. The blended feedstock is distilled in the vacuum distillation unit at a pressure that is less than 50 Torr, and a Petition 870250015048, dated 24 / 02 / 2025, page 26 / 60 19 / 20 temperature which is lower than the boiling point of the blended raw material.

[048] One or more gas oils are cracked in a catalytic cracker and in a hydrocracker to generate one or more of gasoline, a material in the naphtha range and / or one or more middle distillates. The gasoline, the material in the naphtha range and / or the one or more middle distillates are treated and blended to generate one or more of gasoline, kerosene, diesel, heating oil and / or solvents.

[049] The benefits of this disclosure include reusing plastic to reduce the use of newly produced hydrocarbons (such as crude oil); restoring plastic waste to high-value virgin plastic levels with low energy expenditure; reusing plastic in existing refining and petrochemical processing infrastructure; extending the service life of existing refining and petrochemical processing systems; reducing plastic waste and carbon released into the atmosphere; reducing land, air and water pollution (e.g., oceans); efficiently reducing carbon footprints for refining and petrochemical processing systems; greater cost efficiency; and greater operational efficiency for refining and petrochemical processing systems.

[050] As an example, it is believed that blending plastic feedstock (which may include pulverized plastic powder and / or melted plastic) into feedstock^) of petrochemical refining and processing systems can save a system operator $285 per metric ton of plastic supply (e.g., recycled plastic or waste plastic), as compared to using crude oil produced in place of plastic feedstock.

[051] It is contemplated that one or more of these aspects disclosed in this document may be combined. Furthermore, it is contemplated that one or more of these aspects may include some or all of the benefits mentioned previously. As an example, this disclosure contemplates that one or more of these aspects, Petition 870250015048, dated 24 / 02 / 2025, page 27 / 60 20 / 20 characteristics, components, operations and / or properties of the plastic converting system 100, the plastic converting unit 110, the processing system 200 and / or the method 300 can be combined.

[052] It will be appreciated by those skilled in the art that the preceding embodiments are illustrative and not limiting. It is intended that all modifications, permutations, improvements, equivalents and enhancements, therefore, that are evident to those skilled in the art from a reading of the descriptive report and a study of the drawings, are included in the scope of the disclosure. It is therefore intended that the following appended claims may include all such modifications, permutations, improvements, equivalents and enhancements. The present disclosure also contemplates that one or more aspects of the embodiments described herein may be substituted by one or more other described aspects. The scope of the disclosure is determined by the following claims. Petition 870250015048, dated 24 / 02 / 2025, page 28 / 60

Claims

1 / 4 CLAIMS 1. Plastic converting unit CHARACTERIZED in that it comprises: a primary hopper configured to receive a supply of plastic; a primary shredder comprising an outlet and an inlet coupled to an outlet of the primary hopper, wherein the primary shredder is configured to shred the plastic supply to a first granule size that is less than 5 millimeters; a primary classifier comprising an outlet and an inlet coupled to the outlet of the primary shredder, the primary classifier configured to separate a portion of the plastic supply that is larger than the first granule size; a secondary hopper comprising an outlet and an inlet coupled to the outlet of the primary classifier, the secondary hopper configured to receive the first granule size plastic supply from the primary classifier;a secondary granulator comprising an outlet and an inlet coupled to the outlet of the secondary hopper, wherein the secondary granulator is configured to grind the plastic supply into a plastic feedstock having a second granule size that is within a range of 10 nanometers to 0.1 microns; and a secondary classifier comprising an outlet and an inlet coupled to the outlet of the secondary granulator, wherein the secondary classifier is configured to separate the plastic feedstock to remove a portion that has a granule size that is greater than 10 nanometers to 0.1 microns and generate a plastic feedstock.

2. Plastic converting unit, according to claim 1, CHARACTERIZED in that it further comprises: Petition 870250015048, dated 24 / 02 / 2025, page 29 / 60 2 / 4 a tertiary hopper comprising an outlet and an inlet coupled to the outlet of the secondary classifier; a tertiary grinding mill comprising an outlet and an inlet coupled to the outlet of the tertiary hopper, wherein the tertiary grinding mill is configured to grind the plastic raw material to a third granule size that is within a range of 7 nanometers to 10 nanometers; and a tertiary classifier comprising an outlet and an inlet coupled to the outlet of the tertiary grinding mill.

3. Plastic converting unit, according to claim 2, CHARACTERIZED in that it further comprises: a first pneumatic conductor line coupled between the outlet of the secondary classifier and the inlet of the tertiary hopper; and a second pneumatic conductor line coupled between the outlet of the tertiary classifier and an inlet of a plastic storage tank.

4. Plastic conversion unit, according to claim 1, CHARACTERIZED in that it further comprises one or more heaters comprising an inlet coupled to the outlet of the primary classifier, wherein the one or more heaters are configured to melt a portion of the plastic supply having the first granule size into a molten plastic having a third granule size that is within a range of 7 nanometers to 10 nanometers.

5. Processing system CHARACTERIZED by the fact that it comprises a plastic converting unit coupled to one or more raw material lines, wherein the plastic converting unit comprises: a primary hopper configured to receive a supply of plastic; a primary shredder comprising an outlet and an inlet coupled to an outlet of the primary hopper, wherein the primary shredder is configured to shred the plastic supply to a first granule size that is smaller than 5 millimeters; a primary classifier comprising an outlet and an inlet coupled to the outlet of the primary shredder, the primary classifier configured to separate a portion of the plastic supply that is larger than the first granule size;a secondary hopper comprising an outlet and an inlet coupled to the outlet of the primary classifier, the secondary hopper configured to receive the first granule size plastic supply from the primary classifier; a secondary granulator comprising an outlet and an inlet coupled to the outlet of the secondary hopper, wherein the secondary granulator is configured to grind the plastic supply into a plastic feedstock having a second granule size that is within a range of 10 nanometers to 0.1 microns; and a secondary classifier comprising an outlet and an inlet coupled to the outlet of the secondary granulator, wherein the secondary classifier is configured to separate the plastic feedstock to remove a portion that has a granule size that is greater than 10 nanometers to 0.1 microns and generate a plastic feedstock.

6. Processing system according to claim 5, CHARACTERIZED in that it further comprises a plastic storage tank, wherein the plastic storage tank comprises: an inlet that receives the plastic raw material; and an outlet coupled to one or more raw material lines, wherein the one or more raw material lines comprise one or more of a crude oil line, a vacuum gas oil line or a vacuum bottom line. Petition 870250015048, dated 24 / 02 / 2025, page 31 / 60 4 / 4 7. Processing system according to claim 6, characterized in that the crude oil line feeds an atmospheric distillation unit.

8. Processing system according to claim 6, CHARACTERIZED in that the vacuum gas oil line feeds one or more of a hydrocracker or a catalytic cracker. Petition 870250015048, dated 24 / 02 / 2025, p. 32 / 60

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